Rapid discharge railcar door

Abstract

A rapid discharge railcar door consisted of a plastic main body reinforced by an aluminum frame, and which provides sufficient strength against load-bearing forces and withstands changes in temperature. The main body of the door is made from a polymer in a reaction injection molding process. The door reduces the overall weight of the railway car, thus allowing more coal to be shipped per car.

The invention is hereby claimed as follows:  
     
       1. A discharge door for selectively opening and closing a discharge opening in a railcar comprising: 
       an aluminum frame having hinge means at one end and an actuating beam at the other end,  
       and a main body of polymer molded over the frame by a RIM process to define a generally planar surface on the top side facing the interior of the car to close the opening and a ribbed surface on the bottom side to further reinforce the body.  
     
     
       2. The discharge door of claim  1 , wherein the polymer is a lightweight thermoset material. 
     
     
       3. The discharge door of claim  1 , wherein the hinge means includes spaced apart hinge members not covered by the polymer. 
     
     
       4. The discharge door of claim  1 , wherein the actuating beam is tubular. 
     
     
       5. The discharge door of claim  4 , wherein the tubular beam is box-shaped. 
     
     
       6. The discharge door of claim  4 , wherein the tubular beam is box-shaped and extends from one side of the main body for interconnection with another door to operate as a set for a pair of side-by-side openings. 
     
     
       7. The discharge door of claim  1 , wherein a lip is formed peripherally to coact with the discharge opening to close same against leakage of coal. 
     
     
       8. The discharge door of claim  1 , which further includes a liner on the planar surface of an abrasion-resistant material. 
     
     
       9. The discharge door of claim  8 , wherein the liner is of a UV resistant UHMWPE. 
     
     
       10. The discharge door of claim  9 , wherein the UHMWPE is abrasion-resistant with a non-sticking surface. 
     
     
       11. In a hopper coal car having a bottom with a plurality of discharge openings, a plurality of discharge doors for selectively opening and closing said openings, the improvement in said doors wherein each door comprises 
       an aluminum frame having hinge means at one end and an actuating beam at the other end,  
       and a main body of polymer molded over the frame by a RIM process to define a generally planar surface on the top side facing the interior of the car to close the opening and a ribbed surface on the bottom side to further reinforce the body.  
     
     
       12. The combination of claim  11 , wherein the polymer is a lightweight thermoset material. 
     
     
       13. The combination of claim  11 , wherein the actuation beam is tubular. 
     
     
       14. The combination of claim  11 , wherein the actuation beam is box-shaped. 
     
     
       15. The combination of claim  11 , which further includes a liner mounted on the planar surface of the door. 
     
     
       16. The combination of claim  15 , wherein the liner has a non-stick surface facing the interior of the car. 
     
     
       17. The combination of claim  16 , wherein the liner is of a UV-resistant UHMWPE. 
     
     
       18. The combination of claim  11 , wherein the discharge openings and doors extend transversely of the car. 
     
     
       19. The combination of claim  11 , wherein the discharge openings and doors extend longitudinally of the car. 
     
     
       20. In a hopper coal car having a bottom with a plurality of discharge openings, a plurality of discharge doors for selectively opening and closing said openings, the improvement in said doors wherein each door comprises 
       an aluminum frame having hinge means at one end and an actuating beam at the other end,  
       and a main body of polymer molded over the frame to define a generally planar surface on the top side facing the interior of the car to close the opening and a ribbed surface on the bottom side to further reinforce the body.  
     
     
       21. In a hopper coal car having a bottom with a plurality of discharge openings, a plurality of discharge doors for selectively opening and closing said openings, said discharge openings and doors extending transversely of the car, the improvement in said doors wherein each door comprises: 
       an aluminum frame having hinge means at one end and an actuating beam at the other end,  
       and a main body of polymer molded over the frame by a RIM process to define a generally planar surface on the top side facing the interior of the car to close the opening and a ribbed surface on the bottom side to further reinforce the body,  
       wherein the beam includes an extension at one side of the main body, and connecting means interconnecting the beam extensions of a pair of doors in side-by-side relation as a set for a pair of transversely spaced apart discharge openings.  
     
     
       22. The combination of claim  21 , wherein the connecting means includes a bracket attached to the beam extensions. 
     
     
       23. In a hopper coal car having a bottom with a plurality of discharge openings, a plurality of discharge doors for selectively opening and closing said openings, said discharge openings and doors extending transversely of the car, the improvement in said doors wherein each door comprises: 
       an aluminum frame having hinge means at one end and an actuating beam at the other end,  
       and a main body of polymer molded over the frame by a RIM process to define a generally planar surface on the top side facing the interior of the car to close the opening and a ribbed surface on the bottom side to further reinforce the body,  
       wherein the ends of the beams for each door are substantially flush with the sides of the main body, and connecting means interconnecting a pair of doors in side-by-side relation as a set for a pair of transversely spaced apart discharge openings.  
     
     
       24. The combination of claim  23 , wherein the connecting means includes a spine received in and attached to said beams.